US4376882A - Method of resistance flash butt welding - Google Patents

Method of resistance flash butt welding Download PDF

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Publication number
US4376882A
US4376882A US06/175,685 US17568580A US4376882A US 4376882 A US4376882 A US 4376882A US 17568580 A US17568580 A US 17568580A US 4376882 A US4376882 A US 4376882A
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Prior art keywords
feeding
workpieces
speed
welding
fusion
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US06/175,685
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English (en)
Inventor
Vladimir K. Lebedev
Sergei I. Kuchuk-Yatsenko
Boris I. Kazimov
Vasily F. Zagadarchuk
Vasily A. Sakharnov
Vitaly T. Cherednichok
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/04—Flash butt welding
    • B23K11/046—Apparatus therefor

Definitions

  • the present invention relates to resistance butt welding, and more particularly to a method of resistance flash butt welding of metals.
  • the invention is particularly useful for welding workpieces with relatively large welding surfaces, such as for welding workpieces with relatively large welding surfaces, and such as for welding structures from rolled ferrous metal, tubing, sheet metal at a relatively low set specific power of welding transformers.
  • the method essentially consists in that the workpieces being welded are first fused at an initial constant speed of feeding the workpieces towards each other, and before the upsetting the feeding speed is stepwise or continuously increased from the initial value v 3 to the final value v o .
  • the initial constant speed v 3 can be appropriately adjusted in the course of welding.
  • the fusion is of a low intensity and proceeds with long current interruptions, with the result that a large amount of oxides originates on the surfaces being fused.
  • the metal oxidation is particularly intense at the areas of deep craters, where the gap between the workpieces being welded is the maximum. It is at these areas that the thickest layers of oxides, most difficult to remove in the upsetting are formed.
  • the method enables an adequate quality of joints to be attained with either a stepwise (FIG. 1, a and b) or a continuous (FIG. 1, c and d) increase of the feeding speed.
  • a stepwise (FIG. 1, a and b) or a continuous (FIG. 1, c and d) increase of the feeding speed Both extensive theoretical studies and a vast body of practical evidence have shown that the conditions for producing high-quality joints are the most favourable when the increase of the feeding speed is governed by a wired-in program.
  • the above-described method suffers from a disadvantage consisting in that the duration ⁇ 1 of the period of the increased feeding speed v 2 (FIG. 1) is set as a function of energy characteristics (e.g. current, power) of the fusion process, while no account is taken of the size of the maximum gap where oxide formation during the period of fusion at a constant initial speed is most probable.
  • the desired effect i.e. creation of the conditions for producing high-quality joints, is not in all cases attained for the period of an increased feeding speed.
  • the object of the present invention is to provide a method of resistance flash butt welding of metals, which produces weld joints with a higher, as against the prior art, quality and improved mechanical properties of the metal in the weld zone.
  • the object of the invention is to provide a method of resistance flash butt welding of metal workpieces having relatively large welding sections, which ensures a high-quality joint.
  • a method of resistance flash butt welding of metal workpieces of more than 5 mm in thickness which consists in that the surfaces of the workpieces being welded are fused at a constant speed v 3 of feeding the workpieces towards each other, and the speed of feeding the workpieces is, before the upsetting, increased to the final value v o of the speed v o of feeding, wherein, according to the invention, the duration of the period of the accelerated feeding of the workpieces is (1.0 to 4.0)( ⁇ max/v 1 ), where ⁇ max is the maximum gap being formed between the workpiece surfaces being welded before the increase in their feeding speed and v 1 is the average workpiece feeding speed over the period of its increase.
  • the duration of the period of feeding the workpieces being welded at their final feeding speed v o is (0.1 to 0.5)( ⁇ max/v 1 ), but not more than 3 s.
  • FIGS. 1a, 1b, 1c and 1d show graphs of incease in the workpiece feeding speed for various programs of their feeding.
  • FIG. 2 is a diagrammatic illustration of the welding zone, which shows, in a simplified manner, the process of origination of craters,
  • FIGS. 2a and 2b illustrate a destruction of a contact with a "large” height of projections on the surfaces being fused
  • FIGS. 2c and 2d illustrate specific features of origination of craters on the surfaces being fused with a "small” gap therebetween.
  • the duration ⁇ 1 of the period of fusion at increased speeds v 2 of feeding the workpieces being welded should equal or exceed the fusion time in which the metal of the surfaces, including that on the bottom of the deepest craters, is fully renovated.
  • the time ⁇ 2 of the full renovation of the surfaces being fused is defined by the maximum gap ⁇ max (FIG. 2) between the workpieces being welded before increasing their feeding speed and by the preselected average feeding speed v 1 for the speed increase period, and is expressed by the formula
  • a crater being formed as the result of melting-out of this region will be the deeper, the greater is its area, which is in turn conditioned by the gradient of the temperature field ahead of the fusion front (FIG. 2d).
  • the values of the gradients will differ if the heat removal conditions at the regions will be different.
  • the heat removal rate at the edges of specimens is lower, and hence a crater is shallower, than at the centre of the fusion surface; because of this, the crater depth diminishes as the fusion front migrates from the centre to the edge of the fusion surface.
  • the heating of the contacts is conditioned not only by the heat removal conditions, but also by their conductivity.
  • the conductivity increases with increasing no-load voltage U o , and high values of U o create therefore more favourable conditions for increasing the electric contact area. Besides, a larger amount of metal is melted out per unit time at high voltages.
  • the size of the maximum gap is independent of other welding process variables.
  • varying the fusion rate results only in changing the configuration of craters in the surfaces being fused; as the rate increases, the slope of their edges diminishes, while the depth remains unchanged.
  • ⁇ max and ⁇ are respectively the maximum gap and the thickness of the workpieces being welded in mm
  • U o is the no-load voltage in volts.
  • the maximum transient time such as in welding 20 mm thick workpieces at various degrees of increasing the feeding speed, may amount to 0.3 to 1.0 s. Setting the duration of each stem within this range provides for that the transient processes will proceed over the entire speed increase period.
  • Such a speed increase program features a high power consumption and is therefore inexpedient, particularly in welding thick-walled workpieces.
  • the value of ⁇ 1 must be increased.
  • the current flow interruptions will be the longest and the localization of the fusion process will be observed mainly at the perimeter of the workpieces being fused.
  • the optimum duration ⁇ 1 of the speed increase period may be set within the range of 1.0 to 4.0 of the value of ⁇ 2 .
  • the optimum duration ⁇ o of the feeding speed final step (FIGS. 1b, 1c and 1d) may be set within the range of 0.1 to 0.5 of the value of ⁇ 1 , but to not more than 3 s.
  • the maximum gap between the workpieces reaches the maximun value.
  • the final feeding speed for such workpieces is set as low as possible, and the duration of the fusion period with an increase in the feeding speed is therefore set within the range of (1.0 to 1.2) ⁇ 2 .
  • the maximum gap diminishes.
  • the final feeding speed in joining such workpieces is increased.
  • the value of ⁇ 1 may be therefore increased for the purpose of reducing the set power.
  • the widest range of variation of the value of ⁇ 1 corresponds to thinner-walled workpieces welded at higher speeds.
  • the proposed method allows producing high-quality weld joints featuring stable mechanical characteristics. This has been confirmed by comprehensive tests of the above-listed joints made by the proposed welding method. Thus, all the specimens subjected to a tensile test (more than 350 specimens in all) showed the strength and plastic properties at the level of those of the base metal.
  • the use of the proposed method allows upgrading the stability of mechanical properties of flash butt welds to a level needed for critical weldments, such as large diameter gas and oil pipelines constructed in northern regions and high-pressure steam pipings of thermal power stations.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Arc Welding In General (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
  • Butt Welding And Welding Of Specific Article (AREA)
US06/175,685 1980-08-14 1980-08-05 Method of resistance flash butt welding Expired - Lifetime US4376882A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB8026499A GB2081631B (en) 1980-08-14 1980-08-14 Method of resistance flash butt welding

Publications (1)

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US4376882A true US4376882A (en) 1983-03-15

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US06/175,685 Expired - Lifetime US4376882A (en) 1980-08-14 1980-08-05 Method of resistance flash butt welding

Country Status (6)

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US (1) US4376882A (enrdf_load_stackoverflow)
JP (1) JPS5741889A (enrdf_load_stackoverflow)
DE (1) DE3030126C2 (enrdf_load_stackoverflow)
FR (1) FR2492294A1 (enrdf_load_stackoverflow)
GB (1) GB2081631B (enrdf_load_stackoverflow)
SE (1) SE440756B (enrdf_load_stackoverflow)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110048959A1 (en) * 2009-08-31 2011-03-03 Tennant Company Electrochemically-Activated Liquids Containing Fragrant Compounds

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3706316C2 (de) * 1987-02-27 1994-07-21 Stahlberg Roensch Gmbh & Co Kg Verfahren zum Abbrennstumpfschweißen von stumpf miteinander zu verbindenden Teilen
DE3924162A1 (de) * 1988-09-23 1990-03-29 Fischer Ag Georg Verfahren zum abbrennstumpfschweissen von hochgekohlten werkstoffen, insbesondere gusseisen mit kugelgraphit

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1006547B (de) 1952-12-17 1957-04-18 Licentia Gmbh Verfahren zum Abbrennschweissen unter Regelung der Vorschubgeschwindigkeit nach den elektrischen Zustandsgroessen an der Schweissstelle
US3790739A (en) * 1972-07-10 1974-02-05 V Lifshits Machine for continuous flash butt-welding of parts

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1053634A (enrdf_load_stackoverflow) * 1900-01-01
US3528340A (en) * 1968-08-28 1970-09-15 Mesta Machine Co Control arrangement for flash welder and the like
SU904938A1 (ru) * 1978-12-19 1982-02-15 Ордена Ленина И Ордена Трудового Красного Знамени Институт Электросварки Им. Е.О.Патона Способ контактной стыковой сварки оплавлением

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1006547B (de) 1952-12-17 1957-04-18 Licentia Gmbh Verfahren zum Abbrennschweissen unter Regelung der Vorschubgeschwindigkeit nach den elektrischen Zustandsgroessen an der Schweissstelle
US3790739A (en) * 1972-07-10 1974-02-05 V Lifshits Machine for continuous flash butt-welding of parts

Non-Patent Citations (3)

* Cited by examiner, † Cited by third party
Title
Kuchuk-Yatsenko et al; "Method for Continuous Resistance Flash Butt Welding of Articles Having a Large Cross Section"; Kiev, 1968; pp. 4 to 10. *
Kuchuk-Yatsenko et al; Continuous Resistance Flash Butt Welding; Kiev, 1976; pp. 134-135. *
Welding Handbook Sixth Edition, Section Two AWS, New York 1969, Section 27.3. *

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110048959A1 (en) * 2009-08-31 2011-03-03 Tennant Company Electrochemically-Activated Liquids Containing Fragrant Compounds

Also Published As

Publication number Publication date
JPH0218954B2 (enrdf_load_stackoverflow) 1990-04-27
SE440756B (sv) 1985-08-19
JPS5741889A (en) 1982-03-09
FR2492294B1 (enrdf_load_stackoverflow) 1982-10-29
DE3030126A1 (de) 1982-03-18
GB2081631B (en) 1985-04-03
DE3030126C2 (de) 1985-11-21
SE8005581L (sv) 1982-02-07
GB2081631A (en) 1982-02-24
FR2492294A1 (fr) 1982-04-23

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